Unitary floor and roof construction and method of assembly



March 16, 1965 A. SOLNICK 3,173,226

TAPY FLQOR ROOF C N ND METH OF ASSEMBLY d Jan. 10, 1962 Sheets-Sheet 1 March 16, 1965 A SOLNICK 3, 3,

UNITARY FLOOR AND ROOF CONSTRUCTION AND METHOD OF ASSEMBLY Filed Jan. 10, 1962 4 Sheets-Sheet 2 FIG.2

INVENTOR.

ABRAHAM SOLNI CK ATTORNEY A. SOLNICK March 16, 1965 4 Sheets-Sheet 3 Filed Jan. 10, 1962 m 1 1| L F- 2 2 n ll 1 H\ 3 I. 4 r u u s Y3 n x n n m I 5 a n n 3 I a, m u 3 .V.||||-|I l|.||| M: 3 Q04 I 2 :III I 3 I ll l a I 6a a n n m A f o l l l 7 M m m n a? B 2 r I A, il 3 INVEN TOR. ABRAHAM SOLNICK FIG.6

ATTORNEY March 16, 1965 A. SOLNICK 3,173,225

UNITARY FLOOR AND ROOF CONSTRUCTION AND METHOD OF ASSEMBLY Filed Jan. 10, 1962 4 Sheets-Sheet 4 INVENTOR. ABRAHAM SOLNICK ATTORNEY United States Patent Ofiice 3,173,226 Patenteci Niel. 16, 1965 3 173,226 UNETARY FLGOR Alil) ROOF CONSTRUCTIQN AND METHOD 9F ASSEMBLY Abraham Solnick, 157-48 22nd Ave, Whltestone 57, N.Y. Filed Jan. 10, 1962, Soy. No. 165,998 Claims. (Cl. 50-61) The subject matter of this invention relates to the field of building construction, and has for its objective the construction of combination floors and ceilings, and of roofs, by the assembly of a plurality of basic precast units of concrete, tile or the like, in combination with interlocking pro-stressed and post-tensioned metal reinfocernents in a particular manner, resulting in a completed floor-ceiling or roof of any specified size, and of strength to resist anticipated stresses and support anticipated loads.

In the present state of the art of building construction floors are customarily laid by preparing first a framework, Within which reinforcing steel rods are laid out and around which concrete is then poured. Following the hardening of this concrete specific finishes are applied to the upper surface for final flooring, while specific finishes are applied to the under surface to form the completed ceiling of the lower story, as is well known in the art. Some attempts have been made to construct flooring by the assembly of pro-cast units or slabs of concrete or tile laid across a. series of joists. These units have generally been provided with angled sides and, after assembly, require grouting to fill the interstices between the units in order to provide a flush flooring. Such construction is complicated, cumbersome and expensive. Concrete floors are also constructed of large pre-cast members which span in one piece between supports. Such members are heavy and require large equipment for installation.

By my invention, however, I provide a means and a method for unitary construction of floors and roofs, and, in modified form, walls and beams, which eliminates all of the problems created with previous unitary assemblies, as well as a construction which is superior to, and more economical than, the present standard methods of such construction.

My invention consists essentially of the combination of particularly constructed, standardized units of pre-cast concrete, assembled together with reinforcing steel rods and channels in interlocking relationship to form a floor or roof construction of any designated size, shape and strength, depending upon the number of units used and upon the number and size of reinforcing steel rods used in the interlocking of the units and channels. The units are added to the construction progressively, each unit being locked to the units previously installed, and post-tensioned in the process of assembly to form a floor reinforced and partially pre-stressed in two directions, at both the top andbottom of the unit. Construction in this manner eliminates the need fortemporary supports, centering or formwork during the construction, in whole or in part. The units are so constructed that their upper and lower surfaces are finished and reversible, so that either surface may be used for'the floor surface or for the ceiling surface of the lower story. They are also designed to provide a series of interior ducts or voids adapted to carry electric, telephone and other lines, and provided with other novel features, as will hereinafter appear.

It is the principal object of my invention, therefore, to create a floor-ceiling or roof construction comprising a plurality of uniform concrete units in combination with reinforcing rods and channels having the structural advantages of cast-in-place concrete, to wit; continuous twoway fiat slab construction together with the advantages of pre-cast construction.

A second important feature of my invention is to create unitary floor-ceiling and roof constructions of various sizes, shapes and strengths by varying the number of units employed and the size and number of reinforcing rods interlocking these units.

A third important object of my invention lies in my method of constructing and assembling unitary floors and roofs.

A fourth important object of my invention lies in the provision of construction units whose upper and lower surfaces may alternately be used as floor or ceiling surfaces.

A fifth important object of my invention lies in the provision of a unitary floor or roof construction in which the component units are post tensioned in the process of assembly to form a pro-stressed construction.

A sixth important object of my invention lies in the provision of complete floors provided with an internal network of connected ducts or voids adapted to carry electrical and telephone cables, and the like.

A seventh important object of my invention lies in the creation of a unitary floor or roof construction which can be assembled without temporary supports, centering or formwork during installation, and which can be installed with a minimum of skilled labor.

An eighth important object of my invention lies in the provision of a floor or roof construction which can be disassembled and re-used Without damage, or loss, of any of its'parts.

A ninth important object of my invention lies in the construction of a unitary floor or roof which is completely fire-proof and without exposure of any metal.

A tenth important object of my invention lies in the provision of a unitary floor or roof construction of which the units and parts are uniform and can be mass-produced for greater economy.

Other salient objects, advantages and functional features will become more readily apparent from an examination of the following specification, taken with the accompanying drawings, wherein:

FIG. 1 is a perspective view of a floor construction made according to my invention, partially broken away to show interlocking assembly of reinforcing rods and channels;

FIG. 2 is a perspective, exploded view of one of the construction units of FIG. 1, as well as the metal reinforcements by which it is interlocked with the abutting units;

16. 3 is a perspective view of a modified form of the construction unit shown in FIG. 2;

FIG. 4 is a top view of another floor constructed in ac cordance with my invention, partly broken away to show the arrangement of the interlocking channels;

FIG. 5 is a cross-sectional view, taken on lines 5-5 of FIG. 4;

FIG. 6 is an enlarged cross-sectional view, taken on lines 65 of FIG. 4;

FIG. 7 is a side View of a modified form of construction showing an arced roof made according to my invention; and

FIG. 8 is an enlarged cross-sectional view, partly fragmentary, of the embodiment shown in FIG. 7, and partly broken away to show inner construction.

Similar reference characters designate similar parts throughout the different views.

It is to he understood that the composition of the units, as well as the composition and size of the interlocking steel rods and channels are pre-determined, in accordance with recognized engineering standards, to provide for the necessary stresses, tensions and loads which the completed floors and roofs are required to suffer and sustain.

Referring now to the drawings showing preferred embodiments of floor construction, the floors and comprise each a plurality of precast concrete units 11, assembled in interlocking, tensioned relationship by means of the interconnecting tie rods 12 and shear channels 13. The units 11 are uniform, as will hereinafter be explained, and are preferably factory pro-cast of concrete blocks made of cement and standard or light weight aggregates. They may, instead, be tiles of baked clay,- or any other material suitable for the purposes intended. Although specific size is not critical, in this preferred embodiment each basic unit 11 is 12 inches square and 8 inches high, having an approximate weight of 64 pounds, with all four sides 14 ground, and identical upper and lower surfaces 15 so that the top and bottom of each unit 11 is interchangeable. Each unit 11 is provided with a recessed slot 16 in all of its sides 14, running parallel with and adjacent to its upper surface 15 and with an identical slot 16 running in the same manner adjacent its lower surface 15, as shown in FIG. 2. A series of 12 parallel openings or bores 17 are provided in the unit 11, running in the same direction, extending through the upper slot and lower slot 16, six bores 17 through the upper slot 16 and six through the lower slot 16, in series of three bores each adjacent each corner of the unit 11. Another series of 12 parallel bores 18 are provided in the unit 11, running in a direction transverse or at right angles .to the first 12 bores 17, and arranged in manner similar to the arrangement of the bores 17, the bores 17 running on a different plane than the bores 13 through the slots 16, so that the bores 17 clear the bores 18 where they would ordinarily cross. A rectangular opening or void 19 is provided through the central section of each unit 11, running parallel with the bores 17, the geometrical configuration of the unit 11 being such that it has no proper top or bottom and, by suitable turning, the bores 18 and 17, and the central void 19, may be aligned in any direction in relationship to adjoining units 11 in the construction, so that the bores 17 and 13 of each unit 11 come into appropri- 1 ate registry, as well as the voids 19 to form a continuous channel or duct 37.

Steel shear channels 13 are provided for engaging and interlocking the adjoining units 11, dimensioned to fit into the slots 16 of the adjoining units 11, when joined together, in a snug-fit relationship, and designed to resist direct vertical shear between the surfaces 15 of the adjoining units 11. The shear channels 13 are all uniform in size, as shown in FIG. 2, except for certain channels 21a of one-half length which are used for commencement of the assembly, as will hereinafter be shown. Each shear channel 13 is of a length equal to that of two units 11, less the depth of the slots 16, with closed ends 22 by which adjoining channels 13 are bolted together through holes 23 by means of bolts 24, the bolts 24 having each an area (after allowance for thread) equal to the net area of the channel 13.

Each channel 13 is further provided with bores 25 in its bodysection, which are adapted to come in registry with the bores 17 or 18 of the units 11 when the channel 13 is recessed within the appropriate slot 16. It is to be noted that the bores 25 are off center, so that when the channel 13 is recessed in the side of unit 11 having bores 17 they will come in registry with the bores 17, while, when reversed and recessed in the side of the unit 11 having the bores 18, the bores 25 will come in registry with the bores 18. An additional bore 26 is provided centrally in each channel 13 adapted to register with the end 22 of a channel 13 at right angles to the first channel 13, to be locked together by means of a bolt 24.

For interlocking and pre-stressing the units 11 and the channels 13 together there are provided a plurality of steel tie rods 12, of uniform length, as shown in FIG. I and FIG. 2. Each of the tie rods 12 is round and of a length slightly shorter than the length of the unit 11, and of a maximum diameter smaller than the diameter of the bores 17 and 18. In FIG. 2 there are shown a full complement of tie rods 12 for the series of lower bores 17 and 18, while in FIG. 1 a minimum number of tie rods 12 are shown, for simplicity and clarity. It is to be understood that, since the tie rods 12 take most of the stress and weight in the complete system, the number and thickness of tie rods 12 used for a particular floor or roof construction will depend upon the Weight load it is to carry, as Well as stress and various other engineering factors to be considered, all of which are to be determined on the basis of known engineering methods. This also determines whether tie rods 12 are used through both upper and lower bores 17 and 18, or through the lower bores alone, the number used and the size of tie rods 12 to be used.

Each of the tie rods 12 is provided with an external thread 28 at each end, the thread being of a particular length, as will hereinafter be explained. The tie rods 12 are secured together in the completed construction to form continuous reinforcing rods extending throughout the length and width of the full floor, by means of hexagonal coupler nuts 29. These coupler nuts 29, as shown in FIGS. 2 and 6, are no longer than twice the depth of the unit slots 16, but of a length suificient to receive an adequate length of tie rod 12 entering each end thereof, and are provided with an internal thread 30 adapted to engage the external threads 28 of the tie rods 12, the

, cross-sectional area of metal in the coupler nut 29 being provided equal to that of the tie rod 12, after allowance for thread, so that the engagement of the interlocked tie rods 12 and coupler nuts 29 will create continuous reinforcing rods of uniform strength.

In addition to the units 11 heretofore described there are provided modified units 11A, as shown in FIG. 3. The modified unit 11A is identical with unit 11 in all respects of size, shape and construction, except that it is further provided with a central void 31 running therethrough at right angles to the void 19, identical in size and shape, and intersecting it in the center of the unit 11A, and also provided With a central opening or void 32 running through the unit 11A from the upper to the lower surface 15 at right angles to and intersecting both voids 19 and 31, with surface openings 33 to provide floor and celing outlets for wires and cables running through the ducts or channels to be created by the combination of interlocking units 11, as will hereinafter be shown.

In the construction of a unitary floor, in accordance with my invention, calculations are first made to determine the strength of the floor required, as well as the stresses to which it is to be subjected and the load it is required to carry. In accordance with such calculations the size, composition and number of tie rods 12 necessary for interlocking the units 11 of the floor 10 or 20 will be determined, in a manner well known in the art. In the construction of FIG. 1 the unitary floor 10 is supported upon walls 34, it being unnecessary to secure the units 11 thereto, as shown. In the construc tion shown by FIGS. 4 and 5 the floor 20 is supported upon 4 I beams, 35 and 35a, to which vertical plates 36, and 36a, are bolted, and to which the terminal units 11 are bolted, as shown.

' Referring now to the fioor construction shown in FIGS. 46, the first unit unit 11a is laid upon the corner formed by joining beam 35 and 35a, against the vertical plates 36 and 36:: which are bolted to the respective beams 35 and 35a. Upper and lower shear channels 13a are inserted into the upper and lower slots 16 which are parallel to the plate 36, extending beyond the unit 11a. Tie rods 12 are then passed through the openings 25 in the channels 13a and through the bores 17 of the unit 11a, to protrude beyond the plate 36, where they are secured by coupler nuts 29. Coupler nuts 29 are then threaded upon the free ends of the tie rods 12 and tightened a pre-determined degree with a torque wrench, to secure the channels 13a to the unit 11a. Short shear channels 21a are then inserted into the exposed slots 16 parallel to the vertical plate 36a, tierods 12 are passed through the openings 25 and bores 18 to protrude from aligned openings in the vertical plate 36a, and secured thereto by coupler nuts 29. Coupler nuts 29-are then added to the exposed ends of the tie rods 12 Within the channels 21a, similarly tightened with a torque wrench. A second unit 1112 is then fitted against unit 11a so that the channels 21a and 13a fit within its abutting slots 16. Channels 13b are then recessed Within the exposed slots 16 of unit 1112, one half of these channels 13b extending beyond the unit 11b, across channels 13a, as shown. T ie rods 12, with attached coupler nuts 29 then have their free ends inserted through the openings 25 of channels 13b and through bores 18 of unit 11b to engage the coupler nuts 29 previously installed. Similarly, tie rods 12 with attached coupler nuts 29 are passed through the openings 25 in channels 13a and bores 17 of unit 11b to engage the coupler nuts 29 previously installed. In the same manner additional units 11 are added to the progressive line of units 11 attached to the plate 36, with alternating channels 13 and 21, until a complete first line of units 11 is installed, reaching across the room and resting upon the opposing beams 35a, as well as the beam 35. A second row of units 11, with interlocking channels 13 and tie rods 12, is progressively secured to one another and to the first row of units 11, with the tie IOds 12 post tensioned to the extent necessary to provide adequate steel reinforcement support to the concrete units 11, according to recognized engineering standards. Where the ends of the channels 13 and 21 meet and intersect the converging ends are secured to each other by means of the bolts 24 through the respective end openings 23 and central openings 26 of the channels 13 and 21, to form continuous intersecting shear channels. It is to be noted that, except for the peripheral area of the-floor 2%, where alternate shear channels 21 are required to establish the pattern, the continuous lines of criss-crossing channels 13 form an interlocking pattern of shear channel support for each unit 11, as well as for the complete floor 20, each unit 11 tied to each adjoining unit 11 on each of its sides by a different channel 13, as shown in FIG. 4.

In FIG. 6 there is shown the interlocking relationship of the channels 13, tie rods 12 and units 11.

Referring once more to FIGS. 4-6, the units 11 are so placed with respect to one another that the central voids 19 form continuous ducts 37, extending through the length of the floor. Electric or telephone cables, or other conducting means may be passed therethrough. Where it is desired to provide a floor, or a ceiling, outlet for such cables, a unit 11A replaces the unit 11 in the construction. Also, where it is desired to provide a secondary duct 38, intersecting one of the ducts 37, the units 11 of the line to provide the secondary duct are merely installed with the central voids 19 running at right angles to the voids 19 in the other rows of units 11, as more particularly shown centrally in FIGS. 4 and 5.

In the installation of floors made according to my invention, in addition to shear channels 13 provided in both the upper and lower slots 16 of the units 11, the greater number and size of the tie rods 12 are used through the lower slots 16 and bores 17 and 18, to provide for positive steel reinforcement of the floor, since the lower portion carries the greatest load and stress, while the number of tie rods 12 used through the upper bores 17 and 13 may be reduced in number. Where, however, the floor passes over and rests'upon an intermediate beam or joist 35, as shown in FIG. 5, negative reinforcement may require the same steel reinforcement of tie rods 12 through the upper bores 17 and 18 as well as through the lower bores 17 and 18.

The floor construction shown, for illustration, is an 6 individual floor, but it is to be understood that continuous flooring for an entire building, as well as complete roofing-may be made in the same manner for each story thereof, the undersurfaces of the units 11 providing finis-hed ceilings for the floors below. It can also be seen that the units 11 are so closely compressed together by post tensioning that their edges merge to form a continu ous concrete flooring and ceiling, with no 'meta'l exposed.

Coming now to the modified embodiment of an arced or curved roof, as shown by FIGS. 7 and 8, there is shown a roof construction comprising supporting concrete beams 40 and an arcuate roof 41 constructed of units 11. This construction is similar to the construct-ion of the floors 10 and 26 previously described, with the exception, however, that metal strips '42 are disposed between the upper sides of the adjoining units 11, in a direction per- 'pendicular to the line of curvature, the thickness of the metal strips 42, and the number of uiiits 11 required to span between the beams 40 determining the arc of curvature. As shown by FIG. 8, the beams 40' are of poured concrete, in which are embedded metal couplings 43, internally threaded toengage the ends of tie rods 12, and aligned in the beams 40 to register with the bores 17 or 18 of the units 11. A ledge 44 acts as a support for the first line of units 11, wmle the progressive lines of units 11 added are secured together, and post t'ensioned, by the interlocking engagements of the channels 13 and tie rods 12. It can readily be appreciated in this connection that, instead of strips 42, the units 11 themselves can be so modified in construction as to have their tops wider in one direction than their bottoms, in which event the insertion of metal strips 42 would be unnecessary.

While the foregoing has been entirely devoted to the means and method of fioor and roof construction, to be made with presently existing beam and girder constructions, my invention may be modified to create a beam and girder system to support the described construction. This may be done by using units 11, channels 13 and tie rods 12 similar to those previously described but of greater dimension and strength, and assembled in the same manner.

A further significant feature of my invention, as canbe readily understood, is to be found in the ease of disassembly of the fiooror roof construction, whereby the component parts may be re-used for construction elsewhere. By reversing the processof assembly the tie rods 12 are uncoupled and removed from each unit 11, togeth er with the channels 13, and the unit 11 removed from the assembly. The next unit is removed in the same manner, until the entire floor is removed.

Further features may be found in that special floor and ceiling finishes may be applied to the surfaces of the units 11 at the factory. A further significant feature is that adhesives may be applied to the edges of the units to bond them together in the process of being installed, the post-tensioning process insuring firm flush contact during setting.

While the embodiments thus shown and described are preferred embodiments, it is to be clearly understood that they are not intended as limitations, but that my invention encompasses all of the features of novelty possible within the scope of the disclosure. Various changes may be made in the construction, composition and ar rangement of parts without limitation upon or departure from the spirit and scope of the invention, or sacrificing any of the advantages thereof inherent therein.

Having described my invention, I claim:

1. A floor construction or the like comprising a plurality of identically shaped units each provided with peripheral slots and a plurality of bores extending through the body thereof and opening into the slots, channel members arranged at right angles to each other bridging pairs of adjacent units in staggered arrangement with said channel members seated in aligned slots formed by said adjacent units, said channel members being disposed with the ends of transverse channel members abutting the sides of an intermediate channel member and connected nel member, the channel members provided with openings adapted to come in registry with the openings of the unit bores, sectional tie rods disposed through the bores of the units and abutting channel members, and coupler nuts to lock contiguous tie rod ends together.

2. A floor construction or the like, as described in claim 1, each of the building units being provided with a central void extending therethrough in one direction, the units being disposed with the voids running in the same direction to form a continuous central duct through each row of units, for wires, cables and the like.

3. A floor construction or the like comprising a plurality of substantially square building units disposed in successive abutting relationship, each of the units provided with slots around its sides parallel to and adjacent its upper and lower surfaces, a plurality of bores extending through each unit and opening into the slots in one direction and a plurality of bores extending through each unit and opening into the slots in a direction transverse that of the first group of bores and upon a dilferent plane therefrom, channel members arranged at right angles to each other bridging pairs of adjacent units in staggered arrangement with said channel members seated in aligned slots formed by said adjacent units, said channel members being disposed with the ends of the transverse channel members abutting the sides of an intermediate channel member and connected together through an opening in said intermediate channel member, said channel members provided with openings therein equivalent to and adapted to come in registry with the bore openings of the units, a plurality of sectional tie rods disposed crosswise through the bores of the units and the openings in the I 1 channel members, the tie rods extending into the unit slots and provided with threaded ends, and coupler nuts secured to the contacting ends of the tie rods to post-stress the tie rods into continuous, two-way reinforcing rods and to post-stress each building unit to the units abutting the same.

4. A floor construction or the like, as described in claim 3, each of the building units provided with a central void extending therethrough in one direction, the units being disposed with their voids running in the same direction to form a continuous central duct through each row of units.

5. A floor construction or the like, as described in claim 4, selected building units thereof being each further provided with a second central void intersecting the first mentioned void in the same plane, and a connecting void at right angles to the intersecting voids at the point of intersection, the last mentioned void provided with openings in the surfaces of the building unit.

6. A floor construction or the like, as described in claim 5, crossing rows of building units disposed to have their central voids aligned to form continuous ducts intersecting each other, with units common to intersecting rows adapted to provide terminals for wires and cables running through the respective ducts and to receive outlets therefor.

7. A building construction as described in claim 3, each of the building units provided with identical surfaces so that either surface may comprise a floor surface or a ceiling surface for the story below.

8. A floor construction or the like, as described in claim 3, the channel members being so disposed within the building units that each unit is locked to the unit abutting each of its sides by a different channel member.

9. A roof construction as described in claim 3, strips disposed between the upper edges of the building units along one direction to provide curvature to the roof.

References Cited by the Examiner UNITED STATES PATENTS 468,132 2/92 Dieterich 50132 687,105 11/01 Anderson 50263 1,478,309 12/23 Waite 50262 1,862,831 6/32 Ryan 50 404 1,884,462 10/32 Willson 50-389 1,970,414 8/34 Brown 50389 2,202,850 6/40 Guignon 50133 2,695,729 12/54 Vander Heyden 50134 2,751,776 6/56 Streblow et al. 50404 2,925,727 2/ 60 Harris et al. 50389 2,971,295 2/61 Reynolds 50133 FOREIGN PATENTS 546,707 4/56 Belgium.

OTHER REFERENCES Prefabrication Magazine, August 1957, p. 451.

HENRY C. SUTHERLAND, Primary Examiner.

WILLIAM I. MUSHAKE, JACOB L. NACKENOFF,

Examiners. 

1. A FLOOR CONSTRUCTION OR THE LIKE COMPRISING A PLURALITY OF IDENTICALLY SHAPED UNITS EACH PROVIDED WITH PERIPHERAL SLOTS AND A PLURALITY OF BORES EXTENDING THROUGH THE BODY THEREOF AND OPENING INTO THE SLOTS, CHANNEL MEMBERS ARRANGED AT RIGHT ANGLES TO EACH OTHER BRIDGING PAIRS OF ADJACENT UNITS IN STAGGERED ARRANGEMENT WITH SAID CHANNEL MEMBERS SEATED IN ALIGNED SLOTS FORMED BY SAID ADJACENT UNITS, SAID CHANNEL MEMBERS BEING DISPOSED WITH THE ENDS OF TRANSVERSE CHANNEL MEMBERS ABUTTING THE SIDES OF AN INTERMEDIATE CHANNEL MEMBER AND CONNECTED TOGETHER THROUGH AN OPENING IN SAID INTERMEDIATE CHANNEL MEMBER, THE CHANNEL MEMBERS PROVIDED WITH OPENINGS ADAPTED TO COME IN REGISTRY WITH THE OPENINGS OF THE UNIT BORES, SECTIONAL TIE RODS DISPOSED THROUGH THE BORES OF THE UNITS AND ABUTTING CHANNEL MEMBERS, AND COUPLER NUTS TO LOCK CONTIGUOUS TIE ROD ENDS TOGETHER. 